Structural Wall Panels, Engineered for Smarter Building
Fast-track your builds with ultra-insulated, high-performance wall panels. Designed for strength, speed, and sustainability.
Wall Panels Built for Safety & Performance
Our wall panel system is uniquely designed to be both exceptionally strong and lightweight. Each panel is manufactured through a high-pressure injection bonding process, combining a structural polyurethane (PUR) core with durable fibro-cement sheets. The polyurethane core provides outstanding sound absorption and superior fire resistance, ensuring safety and comfort.
Precision-Crafted for Performance
Sizes
Available in 2.7m, 3.0m, and 3.6m
Thickness Options:
104mm
High Insulation Ratings:
Energy Efficiency Star Rating of 7.5 up to 10.5
Reinforced Construction:
Fibre cement sheathing + polyurethane core
Certified Safety:
Fire-safe and cyclone-tested by James Cook University
Rapid Installation:
Panels key together using steel SHS and adhesives
Thermal & Acoustic Control:
Talk to us today on how to achieve a no thermal bridging passive home for consistent comfort all year round
Key features
- High R rating; 108mm wall/floor R4.3 104mm R 5.02 (double industry standards)
- Energy efficiency – highest star rating
- No cavities, no gaps, no thermal leaks
- Indoor and outdoor applications
Available Dimensions
Dimensions – Wall Panels
| Dimensions | Standard Values | Tolerance |
|---|---|---|
| Width | 900mm | +/-5mm |
| Length (Height) | 2700, 3000 & 3600mm | +/-5mm |
| Thickness | 104mm | +/-1mm |
| Core Density (PUR) | 50kg/m³ | +/-2kg/m³ |
Engineering specifications
Our wall panels have undergone rigorous testing and are certified to meet the Building Code of Australia’s fatigue load requirements, as well as achieving the highest possible cyclone rating from the James Cook University Cyclone Testing Centre.
Design Loads
The wall panel system has been tested by James Cook University’s Cyclone Testing Station. The test reports have been analysed by certified engineers to identify and present the following design recommendations.
Axial Loads – Wall Panels
| Panel Dimensions | Max Vert Compressive Load | Ultimate Design Load |
|---|---|---|
| 2400x900x104mm (Standard) | 98 kN | 67 kN |
Racking (Bracing) Load – Wall Panels
| Panel Dimensions | Max Vert Compressive Load | Ultimate Design Load |
|---|---|---|
| 2400x900x104mm (Standard) | 16.1 kN/m | 5.4 kN/m |
Suitable for a wide variety of residential and commercial projects
Available for new housing construction
Can be used to upgrade existing buildings
Fixing method
Our panels are designed for quick and secure installation. Each panel fits neatly into a bottom locator and simply slides into the next panel using a steel SHS locator. Inside, a strong 12mm threaded steel tie rod (cyclone rod) runs through the bottom locator and anchors directly into the foundation for maximum strength.
For added durability, the vertical joints between panels are sealed with a high-strength construction adhesive, creating a solid, weather-tight bond. Finally, a steel channel top plate is fitted and securely tied down to the foundation using the same tie rods, ensuring long-lasting stability even in the toughest conditions.
Wall Cladding Panels
Structural Panel Building Systems has created a unique wall panel system. The wall panels are very strong and lightweight. The panels comprise of a high pressure injection bonding of structural polyurethane PUR between sheets of fibro-cement. The polyurethane core offers excellent sound absorption and exceptional fire resistance. Panels are available in lengths of 2.7m, 3.0m, 3.6m and a thicknesses of 104mm, they are 900mm wide.
Advantages of Structural Polyurethane Foam
Polyurethane structural foam has been in use for more than 50 years to manufacture building and refrigeration panels. It is inert and has a closed cell homogenous structure that is fire retarded with no oxygen to carry flames whilst retaining its insulation values throughout its life, it has been monitored for over 50 years without signs of deterioration. It is used in all domestic refrigerators where the freezer section is normally at minus 20°C. The insulation section is much thicker in our wall roof & floor panels, giving exceptionally high insulation values.
Why Choose Our Wall Panels?
- Proven & Reliable – Over 50 years of trusted polyurethane technology.
- Fire-Safe – Inert, closed-cell core that won’t carry flames.
- High Insulation – Exceptional thermal performance for energy savings.
- Durable – Long-lasting with no signs of deterioration.
- Fast Installation – Simple joining system with strong PU bonding.
- Structural Strength – Load-bearing design for lasting stability.
Frequently Asked Questions
They are fully structural and self-supporting. No timber or steel frame is required, although they can integrate with steel structures where needed.
Yes, our wall panels are cyclone-tested and engineered for use in buildings up to three storeys high.
Panels are connected using a steel SHS key and construction adhesive. A threaded tie-rod system secures them to the base and top plates.
Yes. With high R-values, our panels easily exceed minimum energy requirements from 7.5–10.5 star ratings.
Absolutely. You can finish the exterior with render, cladding, or other treatments just like a traditional wall.
Yes, the fibre cement facing and polyurethane core are both non-edible and sealed, offering strong resistance to pests without chemical treatment.
Ready to Build Faster and Smarter?
Let’s talk about how our wall panels can streamline your next project.
